report on"improving overall efficiency of the cutting machines by implementation of pillars of tpm"

8/9/2019 report on"IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES BY IMPLEMENTATION OF PILLARS OF TPM"

1/51

CHAPTER -1

1


2/51

Fig.no-1:-Company Photo

2

INTRODUCTION TO COMPANY


3/51

In the year 1997, Godrej & Boyce celebrated their centenary year.This dynamic organization has progressed tremendously since its inception and

has been gaining strength consistently. Quality is the hallmark of all the Godrej

products and any product with the 'Godrej' mark represent quality,

dependability & satisfaction to its customers. What now is a gainful industrial

organization was a brainchild of Mr. Ardeshir GODREJ, which through the

help dedicated men with tremendous foresight and finely honed engineering

and marketing skills, has become one of the biggest houses in India.

Godrej also made a significant contribution to self-reliance of the

century by building the engine for the PSLRU locker launched by India. In the

year 1978 Godrej diversified in to the field of chemicals by starting the

manufacturing of soaps and further diversified into production of chemicals for

various industries like textile mills, pharmacies, confectioneries, etc.

The most recent achievement by Godrej was made when it acquired the

ISO 9000, ISO 9001 and ISO 14000 certificate, which former reinforced the

rest of not only the Indian market but also the global market in the product of

Godrej Today Godrej employee over 15,000 people and has grown in to a

multi-core professionally managed group with far reaching service and

distribution network. "Economy and Services are being the main motto of

Godrej they have already diversified in to field of Indian industry thus helping

in the economic growth of the country.

2


4/51

Century old brand name, 'Godrej', it now also provides electronicsecurity systems products and is angered with the supply and installation of the

electronics safes, electronics security alarm systems, access control systems,

closed circuit television systems and very highly sophisticated advanced

electronic surveillance systems.

GODREJ & BOYCE MFG. CO LTD.:-

2

1.1 VAROUS PLANTS IN GODREJ


5/51

It is truly a mullet-faceted company. This is the major collaboration ofGodrej with Boyce Company. The maximum of the business of Godrej is

known by this name. At present all the divisions mentioned below come under

this company.

OFFICE EQUIPMENT (O.E.) DIVISION: -The manufacturing activities in this division are distributed in the

following plants:

Plant 1: Steel processing plant

Plant 4 & 14: Furniture systems plant

Plant 13: Industrial storage system

Plant 17: Security equipment

LOCKS DIVISION: -Plant 18 A

TYPEWRITER DIVISION: Plant 18 B

MATERIAL HANDLING DIVISION: -Plant 16

MACHINE TOOL DIVISION: -Plant 9 & 19

TOOL ROOM DIVISION: -Plant 7

OFFICE AUTOMATION DIVISION: -Plant 19 A

1


6/51

PROCESS EQUIPMENT DIVISION: -Plant 15

This division is located in Plant 15 and it designs and fabricates a large

range of custom-made sophisticated equipment for chemicals, petrochemicals

and fertiliser industries such as heat exchangers, boiler shells, tower internals,

etc., as well as equipment for nuclear and aerospace applications such as parts

of atomic reactor, cryogenic engines and projects of ISRO (Indian Space

Research Organisation).

Fig.no-2:-Heat Exchanger

The process equipment division consists of five main production

departments as follows:

Columns.

1


7/51

Heat exchanger.

Reactors & Vessels.

Aerospace Division.

Trays & tower internals.

Product range

Heavy Walled Reactors

Equipment Internals

Fractionating / Distillation Columns

High Pressure Shell & Tube Heat Exchangers

Custom built Equipment

1
http://www.godrej.com/GodrejNew/Templates/ProcessEquipment/PEDProduct.aspx?NRMODE=Published&NRORIGINALURL=/GodrejNew/GodrejHome/OurCompanies/GNB/IndustrialProducts/ProcessEquipment/overview/Introduction.htm&NRNODEGUID=%7B02F4C33A-B422-4686-BEE0-82464285C1E4%7D&NRCACHEHINT=NoModifyGuesthttp://www.godrej.com/GodrejNew/Templates/ProcessEquipment/PEDProduct.aspx?NRMODE=Published&NRORIGINALURL=/GodrejNew/GodrejHome/OurCompanies/GNB/IndustrialProducts/ProcessEquipment/overview/Introduction.htm&NRNODEGUID=%7B02F4C33A-B422-4686-BEE0-82464285C1E4%7D&NRCACHEHINT=NoModifyGuesthttp://www.godrej.com/GodrejNew/Templates/ProcessEquipment/PEDProduct.aspx?NRMODE=Published&NRORIGINALURL=/GodrejNew/GodrejHome/OurCompanies/GNB/IndustrialProducts/ProcessEquipment/overview/Introduction.htm&NRNODEGUID=%7B02F4C33A-B422-4686-BEE0-82464285C1E4%7D&NRCACHEHINT=NoModifyGuesthttp://www.godrej.com/GodrejNew/Templates/ProcessEquipment/PEDProduct.aspx?NRMODE=Published&NRORIGINALURL=/GodrejNew/GodrejHome/OurCompanies/GNB/IndustrialProducts/ProcessEquipment/overview/Introduction.htm&NRNODEGUID=%7B02F4C33A-B422-4686-BEE0-82464285C1E4%7D&NRCACHEHINT=NoModifyGuesthttp://www.godrej.com/GodrejNew/Templates/ProcessEquipment/PEDProduct.aspx?NRMODE=Published&NRORIGINALURL=/GodrejNew/GodrejHome/OurCompanies/GNB/IndustrialProducts/ProcessEquipment/overview/Introduction.htm&NRNODEGUID=%7B02F4C33A-B422-4686-BEE0-82464285C1E4%7D&NRCACHEHINT=NoModifyGuesthttp://www.godrej.com/GodrejNew/Templates/ProcessEquipment/PEDProduct.aspx?NRMODE=Published&NRORIGINALURL=/GodrejNew/GodrejHome/OurCompanies/GNB/IndustrialProducts/ProcessEquipment/overview/Introduction.htm&NRNODEGUID=%7B02F4C33A-B422-4686-BEE0-82464285C1E4%7D&NRCACHEHINT=NoModifyGuesthttp://www.godrej.com/GodrejNew/Templates/ProcessEquipment/PEDProduct.aspx?NRMODE=Published&NRORIGINALURL=/GodrejNew/GodrejHome/OurCompanies/GNB/IndustrialProducts/ProcessEquipment/overview/Introduction.htm&NRNODEGUID=%7B02F4C33A-B422-4686-BEE0-82464285C1E4%7D&NRCACHEHINT=NoModifyGuesthttp://www.godrej.com/GodrejNew/Templates/ProcessEquipment/PEDProduct.aspx?NRMODE=Published&NRORIGINALURL=/GodrejNew/GodrejHome/OurCompanies/GNB/IndustrialProducts/ProcessEquipment/overview/Introduction.htm&NRNODEGUID=%7B02F4C33A-B422-4686-BEE0-82464285C1E4%7D&NRCACHEHINT=NoModifyGuest


8/51

Fig.no-3:-Heavy Walled Reactor

Fig.no-4:-High Pressure Vessels

2


9/51

Machine shop department is one of the vital departments in the Process

Equipment Division. It possesses machines that are required for machining

the various components of the pressure vessel assembly. The department

produces components that are related to the heat exchanger of the pressure

vessel assembly. The machine shop department is a service department andworks in tandem with other departments of the plant.The components

produced in machine shop department can be given as follows: -

Tube sheets

Baffles

Tie rods

Spacers

Flanges

The various machines used in the machine shop department can be

given as follows:

CNC DRILLING MACHINES: - ARBOGA 1

ARBOGA 2

3

1.2 INTRODUCTION TO MACHINE SHOP DEPARTMENT


10/51

HARTFORD 1

HARTFORD 2

BATLIBOI

KOLB

DRILLING MACHINES:- The Drilling machine is in tends fro

drilling medium to large and heavy work pieces. The machine consists of a

heavy round, vertical column mounted on a large base. The column

supports a radial arm which can be raised and lowered to accommodate

work pieces to different heights.

RADIAL 1,2,3,4,5,6,7

CNC LATHE MACHINE :-

HMT LATHE HORIZONTAL LATHE MACHINES:- The Lathe has got all the

basic parts e.g. Bed, Headstock and Tailstock. The Headstock contains

mechanisms for driving a spindle at multiple speeds. Lathe can feed the tool

both in cross and longitudinal direction with reference to lathe axis. A lathe

receives its power from an individual motor known as motor driven lathe.

BOMBAY LATHE

THREE JAW LATHE

MODULAR LATHE

BECO LATHE

4


11/51

NEW LATHE

VERTICAL LATHE MACHINES:- This type of boring

machine combines the advantages of vertical boring machine and turretlathe. It has an indexable turret lathe mounted the cross rail above the table

for multiple tooling. A four station square turret side head which enables

facing, turning under cutting and many other operations.

VTL1 SINGLE ARM (CNC)

VTL5 DOUBLE ARM (CNC)

VTL6 (FARREL)

HORIZONTAL BORING MACHINE:- In a Horizontal Boringmachine, the work is supported on a table which is stationary and the tool

revolves in a horizontal axis. A Horizontal machine can perform boring,

reaming, turning, threading, facing, milling, milling, grooving, recessing

and any other operation with suitable tools.

VERTICAL MILLING MACHINES:- A Milling machine is amachine tool that removes metal as the work is fed against a rotating

multipoint cutter. In a vertical milling machine position of the spindle is

vertical or perpendicular to the work table. The spindle head can be

swivelled at an angle. This machine is adapted for machining grooves, slots

and flat surfaces.

5


12/51

CHAPTER-2

6


13/51

IMPROVING OVERALL EFFICIENCY OF THE

CUTTING MACHINES

MACHINE 1: BEHRINGER BANDSAW

7

INTRODUCTION TO PROJECT
http://www.directindustry.com/prod/behringer/automatic-band-saw-16375-37310.html


14/51

MACHINE 2: CNC GAS CUTTING MACHINE SUAG

MACHINE DETAILS: ( BEHRINGER BANDSAW )

Morgantown, PA (April 7, 2010) A new line of bandsaws engineered to

accommodate and cut large diameter tubing quickly and efficiently is available from

Behringer Saws, Inc. HBP-800AXL Automatic and HBP-800XL Semi-Automatic Series

Bandsaws allow companies to save on upfront capital expenditures and avoid buying

more expensive bandsaws for everyday cutting while expanding their capability to

specifically cut large tubes when needed.

The HBP-800AXL Automatic and HBP-800XL Semi-Automatic Bandsaws

deliver all the performance and capabilities of standard HBP-800 Series Bandsaws

cutting solid bars and structurals up to 31.5. In addition, these new bandsaws allow for

8
http://www.directindustry.com/prod/behringer/automatic-band-saw-16375-37310.html


15/51

the cutting of tubes up to 39" in diameter. Companies can now purchase a lower cost

bandsaw to handle day-to-day production cutting needs at the standard size range while

utilizing this additional feature to accept new projects requiring the cutting of large

diameter tubing.All HBP-800 Bandsaws are built with strong cast iron frame

construction and a twin column parallel down feed design for proper saw blade

tensioning to deliver quick, efficient and forceful low vibration cutting for smooth cuts.

These bandsaws also come with a heavy-duty roller conveyor for quick and efficient

handling of heavy materials pre- and post-cut.

HBP-800 Bandsaws feature a frequency controlled 14.7 horsepower main drive

motor with a variable speed range of between 55-393 Surface Feet Per Minute (SFM)

which is easily selected at the operators control panel. Hydraulic and hardened clamping

jaws on the bandsaw ensures steady and precise cuts at all speeds.

This bandsaw is available in both automatic and semi-automatic versions and

requires minimal operator intervention as it is controlled by a programmable logic

controller (PLC). It features an easy-to-use operators terminal with diagnostic display,

data entry and program storage. The speed is easily set, controlled and monitored before

and during the cutting process.

Behringer Saws, Inc. provides a full range of sawing and turnkey pre- and post-cut

material handling productivity-enhancing products. Behringer supplies world-class

quality automatic bandsaws to corporations, service centers, job shops and manufacturers

throughout the world. The company also offers the Behringer Eisele brand of manual,

semi-automatic and automatic miter circular cold saws, high performance circular cold

saws utilizing bi-metal or carbide saw blades and CNC miter circular sawing systems.

Also, the Vernet Behringer line of structural fabricating equipment includes high

performance drilling, punching, shearing, notching and marking machines along with

beam coping and drilling and sawing lines.

9


16/51

For more information on the HBP-800AXL and HBP-800XL Bandsaws, contact

Behringer Saws, Inc., 721 Hemlock Road, Morgantown, PA 19543. Call toll-free at 888-

234-7464.

Description of machine : -

Stainless steel and tool steel. Tempered steel, special alloys and aluminum. In

different thicknesses, shapes and diameters. Singly, in bundles of fixed lengths.

Whatever you aim to saw, our HBP, HBV and HBM high-performance and automatic

bandsaw series offer the solution you are looking for. In every cutting range. Despite

their outstanding performance, our machines are all designed to offer maximum

operating simplicity and space savings. And like everything from BEHRINGER, they are

unbeatable in terms of speed, precision and quality.

10


17/51

SPECIFICATION OF BEHRINGER BANDSAW:-

Model HBP 413A

Cutting range 90 round (inch) 16.1

90 flat (W x H) (inch) 19.7x15.7

90 square (W x H) (inch) 15.7x15.7

75 meter left dia. / flat (W x H) (inch) -



Working height (inch) 31.5

Single stroke of the feeding gripper (inch) 15.7

Drive motor (H.P.) frequency controlled 5.4

Cutting speed (FPM) 65-459

Cutting capacities 47.2" x 31.5"

Saw blade dimensions 190x1-1/2x .050

Weight (lbs) 5,170

Space requirement (inch) 116x77

Large dual column - parallel down-feed design

Solid cast bow frame

Cast Meehanite band wheels

Fully automatic hydraulic blade tensioning & carbide blade guides

11


18/51

MACHINE DETAILS: ( CNC GAS CUTTING MACHINE - SUAG)

The RUM is the latest generation of CNC profile cutting machine that combines

the quality of construction of the MAXI machine with the advantages of the price/output

ratio of RUR machine. Standard equipment of the RUM includes all available

automation facilities.

Basic equipment

12


19/51

fully welded beam without bolted joints

linear bearing in cross axis

AC servomotors

digital synchronization in longitudinal axis

BURNY 10 LCD Plus control system with touch screen

membrane keyboard

floating cutting heads

electric ignition

capacitive height control of oxy-fuel torch

automatic gas console

torch selection from control panel

automatic initial height sensing of plasma torch

arc voltage height sensing of plasma torch

parking facility for heads out of cutting area

limit switch in each axis

Optional equipment

plasma system by customer request

pneumatic anti-collision system

pneumatic, plasma or inkjet marker

air cooling of portal frame

control system heating (for winter operation)

SPECIFICATION OF CNC GAS CUTTING MACHINE - SUAG:-

RUM 3500 4000 4500

max. number of torches 6

rail span 3500 mm 4000 mm 4500 mm

cutting width * - 1 torch 3100 mm 3600 mm 4100 mm

13


20/51

cutting width * - 2 torches 3100 mm 3600 mm 4100 mm





cutting length by customer request

min. parallel cut 90 mm

cutting speed 0 - 20000 mm/min.

standard cutting thickness 200 mm

machine width 4100 mm 4600 mm 5100 mm

machine length 1200 mm

machine height incl. rails 1700 mm

cutting table height 700 mm

plasma system by customer request

supply voltage 230V/50Hz

Plate widths 1,000 to 2,000mm

Speed 0 to 8,000mm/min

Track 2,000mm (standard) 1,000mm (optional)

Drives: Longitudinal Rack and pinion Transverse Rack and pinion

Plasma: Upto 200amp plasma system. Full height sense and heavy duty head

Gas and heads: Hi Lo preheat (standard) 2 stage pierce (optional)

Cutters: 2 Maximum

Controller: C.N.C. controller mounted on a pedestal

14


21/51


22/51

CHAPTER-3

16

LITERATURE REVIEW


23/51

Literature Review:

1. METHODS:

Time to process Raw-material.

Lack of proper understanding.

1. PEOPLE:

Lack of availability of designers.

Conflicting mindsets of designers.

Inadequate skill-mapping.

Lack of motivation & understanding.

1. MANPOWER:

Dedicated personnel for planning.

Lesser no. of designers involved.

Dynamics of self-help groups.

1. POLICIES:

Government oriented(Time-consuming) paper work.

Lack of finance to create larger SHGs.

Investment.

1. PLACE:

Time & cost incurred.

Proximity to large markets slightly less.

1. SURROUNDING:

Traditional barriers & mind-sets.

Linguistic barriers(biggest issues).

1. PROCEDURES:

Material constraints.

Requires fine tuning of mind towards market.

Requires deeper market understandings by designers.

17


24/51

1. SKILLS:

Newer skills not impaired.

Imbalance in skills.

18


25/51

19


26/51

CUTTING TORCH:

A cutting torch head is used to cut metal. It is similar to a welding torch, but can

be identified by having three pipes that go to a 90 degree nozzle and by the oxygen-blast

trigger.

20


27/51


28/51

BAND-SAW CUTTING BLADE:

Band-saw Cutting Blade

The typical metal cutting bandsaw machine is used for simple cutting of solid

steel, tubing, and odd shaped material. The material to be cut is mounted in a vise

attached to the bed of the machine.

An electric motor drives the bandsaw blade through a belt and pulley arrangement

from which three speeds may be obtained. The sawing machine frame, upon which the

drive wheel, idler wheel, bandsaw blade, and motor are mounted, pivots from one corner

of the sawing machine bed. The frame is counterbalanced by a tension spring between

the frame and the bed.

Feed is controlled by positioning a sliding weight along a bar fixed to the top side

of the sawing machine frame. A dashpot is positioned between the frame and bed to

stabilize the feed movement and prevent any quick movement of the frame that could

cause damage to the bandsaw blade.

22


29/51


30/51

24

ANALYSIS


31/51

25


32/51

Time study on Behringer Band Saw Cutting M/C

26


33/51

27


34/51

TIME STUDY ON BEHRINGER BAND SAW CUTTING M/C

LOSSES

SR.NO. ACTIVITY TIME in min %

1. Setting if JOB 115 19.79

2. Measurement 83 14.28

3. Operator non availability 35 4.30

4. Crane waiting time 15 2.58

5. M/C down time 313 53.87

6. Tool changing time 30 5.16

TOTAL 581 100

28


35/51

TIME STUDY ON CNC GAS CUTTING M/C - SUAG

29


36/51


37/51

31


38/51

CNC

SUAG CUTTING M/C LOSSES

SR.NO. ACTIVITY TIME in min %

1. Scheduled/Planned Stoppages 698 49.75

2. Setting Time 17 1.22

3. Start-up Losses[mock-up] 288 20.52

32


39/51

4. Minor Stoppage[Time Loss] 20 1.42

5. Non Availability of Material 340 24.24

6. Non Availability of Operator 40 2.85

TOTAL 1403 100

CHAPTER -5

33


40/51

34


41/51

SUGGESTIONS BEHRINGER BAND SAW CUTT I NG M/C:-

Three Major Losses in Behringer:-

1. M/C Down Time.

2. Setting Time.

3. Measurement.

1. M/C Down Time

REASON

Break-down maintenance

SOLUTION

Preventive Maintenance of M/C to be done on time to avoid maintenance while M/C

is in production.

2. Setting time

REASON

Fatigueto Operator in Setting the Job.

SOLUTION

35

SUGGESTION


42/51

Sensors are to be employ on machine.

3. Measurement

REASON

1. Presently measurement is done manually by operator.

2. New measurement type equipment must be procured to minimize measurement time.

SOLUTION

Sensors assembly has to be done near to the machine blade so measurement time will

be minimum.

SUGGESTIONS CNC SUAG CUTTING M/C:-

Three Major Losses in CNC Suag:-

1. Scheduled/Planned Stoppages.

2. Non Availability of Material.

3. Start up Loss[mock-up].

1. Scheduled/Planned Stoppages

REASON

1. Loading Time Of Plate Is Too High.

2. Time consumed for Setting the Job Plate.

SOLUTIONS

1. Loading Time Should Be Minimized By Offline Setting Of Plate.

36


43/51

2. Special fixture to be Designed for Quick Setting of Job Plate.

2. Non Availability of Material

REASON

Improper & Unplanned Stacking of Plates.

SOLUTIONS

1. Proper stacking of plates as per priority.

2. Proper proactive planning to feed the m/c as per plan.

2. Start up Loss[mock-up]

REASON

1. No cleaning before Operator reports the machine.

2. Major time consumed in Test Run.

SOLUTIONS

1. Special Cleaning staff to be provided for cleaning of the m/c before operator reports

on the m/c during each shift.

2. Special Fixture to be made to avoid Test Run.

37


44/51

CHAPTER -6

38


45/51

39

PRO E


46/51

40


47/51

41


48/51

42


49/51

CHAPTER -7

43


50/51

44

CONCLUSIONS


51/51

REFERENCES

report on"improving overall efficiency of the cutting machines by implementation of pillars of tpm"

Documents